System and method for personalizing a card

ABSTRACT

Systems and methods for personalizing data card are disclosed. One embodiment includes a card receiver configured to receive one or more data cards, a control system connected to the card receiver, the control system configured to receive personalization information, an encoder system connected to the control system, the encoder system configured to encode the one or more data cards with at least some portion of the personalization information, a card reader connected to the control system, the card reader configured to read magnetic fingerprint information from the one or more data cards, and the control system configured to store the magnetic fingerprint information.

RELATED APPLICATIONS

The present invention claims priority to U.S. Provisional PatentApplication Ser. No. 60/735,354 filed on Nov. 10, 2005, the disclosureof which is incorporated herein by reference in its entirety.

BACKGROUND

The present invention relates to the transfer of card personalizationinformation over a data network and the embossing of that cardpersonalization information on a card such as a credit card,identification card, or other similar card.

The credit card industry is amongst the industries that print, emboss,or indent useful information on data cards. This information can includecredit card numbers, expiration dates, along with holograms, pictures,corporate logos, etc.

SUMMARY OF THE INVENTION

The present invention relates to a system and method for personalizing acard. In one embodiment, the invention relates to a card personalizationsystem including a card receiver configured to receive one or more datacards, a control system connected to the card receiver, the controlsystem configured to receive personalization information, an encodersystem connected to the control system, the encoder system configured toencode the one or more data cards with at least some portion of thepersonalization information, a card reader connected to the controlsystem, the card reader configured to read magnetic fingerprintinformation from the one or more data cards, and the control systemconfigured to store the magnetic fingerprint information.

In another embodiment, the system relates to a card personalizationsystem including a card receiver configured to receive one or more datacards, a control system connected to the card receiver, the controlsystem configured to receive personalization information, an encodersystem connected to the control system, the encoder system configured toencode the one or more data cards with at least some portion of thepersonalization information, a printer connected to the control system,the printer configured to print at least some portion of thepersonalization information to the one or more data cards, and theprinter configured to print using a printer ribbon comprising one ormore portions, each portion having a different color.

In yet another embodiment, the invention relates to a system forembossing a data card including a first embosser wheel having aplurality of radially extending fingers, each of the fingers configuredto receive a first hammer mechanism and to impart a character to thedata card, a second embosser wheel having a plurality of radiallyextending fingers, the fingers configured to receive a second hammermechanism and to impart a character to the data card, a first motorconfigured to drive the first hammer mechanism, and a second motorconfigured to drive the second hammer mechanism.

In still yet another embodiment, the invention relates to a method ofpersonalizing a data card, including receiving a data card, receivingpersonalization information, encoding the data card with at least someportion of the personalization information, reading a magneticfingerprint of the data card, and storing the magnetic fingerprint.

In another embodiment, again the invention relates to a method ofpersonalizing a data card including receiving a data card, receivingpersonalization information, encoding the data card with at least someportion of the personalization information, reading a magneticfingerprint of the data card, storing the magnetic fingerprint, printingat least some portion of the personalization information to the datacard, transporting the data card from a first location to a secondlocation, embossing or indenting the data card with at least someportion of the personalization information, and determining whether thedata card meets a predetermined criteria and, if not, rejecting thecard.

In a further embodiment, the invention relates to a method ofcommunicating with a card personalization system including receiving arequest for personalization information, the request comprisinginformation identifying a card user, identifying a record based on theinformation identifying the card user, the record comprisingpersonalization information, sending the personalization information,receiving magnetic fingerprint information for a data card associatedwith the card user, and storing the magnetic fingerprint information inconjunction with the record.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a network of card personalization systemsin accordance with one embodiment of the invention;

FIG. 2 is a block diagram of a card personalization system in accordancewith an embodiment of the invention;

FIG. 3 a is a top view of a printer ribbon in accordance with anembodiment of the invention;

FIG. 3 b is a top view of a printer ribbon in accordance with anembodiment of the invention;

FIG. 3 c is a top view of a printer ribbon in accordance with anembodiment of the invention;

FIG. 3 d is a top view of a printer ribbon in accordance with anembodiment of the invention;

FIG. 4 is a perspective view of the card personalization system of FIG.2 in accordance with an embodiment of the invention;

FIG. 5 is a front view of the card personalization system of FIG. 4;

FIG. 6 is a plan view of the card personalization system of FIG. 4;

FIG. 7 is a perspective view of a card embosser in accordance with anembodiment of the invention;

FIG. 8 is a front view of the card embosser of FIG. 7;

FIG. 9 is a flowchart of a process for embossing a card in accordancewith an embodiment of the invention;

FIG. 10 is a block diagram of a memory system in accordance with anembodiment of the invention;

FIG. 11 is a block diagram of a card personalization system inaccordance with an embodiment of the invention;

FIG. 12 is a schematic block diagram of a card personalization system inaccordance with an embodiment of the invention;

FIG. 13 is a flowchart of a process for personalizing a data card inaccordance with an embodiment of the invention;

FIG. 14 is a flowchart of a process for communicating with a cardpersonalization system in accordance with an embodiment of theinvention;

FIG. 15 is a perspective view of the card personalization system of FIG.11 in accordance with an embodiment of the invention; and

FIG. 16 is a plan view of the card personalization system of FIG. 15.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings, embodiments of card personalizationnetworks connecting hosts and card personalization systems areillustrated. Card personalization networks allow communication betweencentral hosts having financial records or other identification recordsand card personalization systems using a variety of protocols. Cardpersonalization systems enable the personalization of cards, oftenhaving a magnetic stripe (magstripe card), with information indicativeof the card user. This information can often include the user's name,account number and the expiration date of the card. The cards to bepersonalized can include credit cards, identification cards and othercards capable of being encoded with personalization information.

The personalization process can be performed by a number of componentsin the card personalization system. For example, the path that a cardpasses through during the personalization process can include a manualinsertion slot or card hopper, a flipper station, an encoder station, aprinter module, a lateral card transport, a card embosser, a magneticfingerprint reference station, a foil tipping station, a transfermodule, a reject card hopper, a card exit transport and/or an exithopper. These components are capable of encoding or enabling theencoding of personalization information to one or more blank cards oftenhaving a magnetic stripe or otherwise capable of storing informationwith the card.

A schematic view of a card personalization network in accordance with anembodiment of the invention is shown in FIG. 1. The card personalizationnetwork 10 includes a central host or server 200 which communicatesdirectly with a plurality of card personalization systems 100 and/or viaa network 202. The card personalization systems 100 can be physicallyremote, located for example at a branch bank, from the central host 200which can be located at a different location such as a central dataprocessing center. In one embodiment, a card personalization system 100requests system information such as card number and expiration date, asubset of the card personalization information, for a particular carduser. The central host 200 can respond by sending the requested systeminformation to the card personalization system 100. The central host 200can accommodate multiple requests simultaneously. While FIG. 1 shows sixcard personalization systems, other embodiments could have as few as onecard personalization system or more than six such systems.

In one embodiment, the central host 200 can communicate with a cardpersonalization system 100 using the XML (extensible markup language)protocol and a proprietary command set. In one embodiment, the physicalconnection can be Ethernet or USB (universal serial bus). In otherembodiments, other protocols and physical mediums can be used to connectthe central host 200 to multiple card personalization systems 100. Forexample, the central host 200 could use a private or public network 202to communicate to any card personalization system 100. In oneembodiment, all or a portion of the data communication over the networkcan be encrypted to protect the privacy of personalization data.Although a star like network topology is shown in FIG. 1, other networktopologies can be used. Rather than a server/client network, a peer topeer network can be used. In a common embodiment, the communication cantake place over a secure private data network.

In several embodiments, the card personalization system 100 can beconnected to input devices including a camera 111, a fingerprint scanner113, a microphone 115, a retina scanner 117, and/or a keyboard 119.These devices can be used to acquire further card personalizationinformation from a user or to acquire access information from anoperator. In one embodiment, connection to these devices is through theuse of a personal computer, which is not shown. In many embodiments, thekeyboard 119 is an input device for entering a PIN (personalidentification number) in the form of a set of numbered buttons. In suchcase, the keyboard can allow the operator or card user to enterinformation unique to a given card user. This unique information cantypically be a PIN for a card user. The card personalization system canstore this unique information and verify the authenticity of theinformation with either the memory local to the card personalizationsystem or a database having user and/or operator information on thecentral host or elsewhere on the network.

A block diagram of a card personalization system in accordance with anembodiment of the invention is shown in FIG. 2. The card personalizationsystem includes a dual card hopper 102, a manual insertion slot 104, aflipper station 106, an encoder station 108, a printer module 110, alateral card transport 112, a card embosser 114, a magnetic fingerprintreference station 116, and a foil tipping station 118. The dual cardhopper 102 and manual insertion slot 104 are both connected to theflipper station 106 via the card path 107. The flipper station 106 isconnected to the encoder station 108 and printer module 110 via the cardpath 107. The lateral card transport 112 is connected to the printermodule 110 and the card embosser 114 via the card path 107. The magneticfingerprint reference station 116 is connected to the card embosser 114and the foil tipping station 118 via the card path 107. In manyembodiments, the components of the card personalization system aremodular and can be removed or additional components can be added. Inother embodiments, the order of the components may also be rearranged.In many embodiments, individual card transport systems (not shown) movethe data cards along the card path. In one embodiment, a single cardtransport system (not shown) moves the data cards along the card pathand/or wherever needed.

In one embodiment, after card personalization information has beenrequested and received for a particular card user, a card enters thecard path 107. The card can either enter via the dual card hopper 102 orthe manual insertion slot 104, each of which can be thought of as a cardreceiver. In other embodiments, the insertion of a card can be broughtabout in other ways. In many embodiments, cards including graphics,embossing and/or other forms of personalization are used. In manyembodiments, a card personalization system is used to modify informationon a previously personalized card, such as modifying a PIN number.

The card can then enter the flipper station 106 where it may be rotatedand aligned in preparation for the encoder station 108. In oneembodiment, the card can then be advanced to the encoder station 108where it is personalized with a unique magstripe and/or smartcard dataas called for by the card personalization information. In oneembodiment, data is recorded on a magnetic stripe located on the card.In another embodiment, data is recorded on a contact IC (integratedcircuit) on the card. In a further embodiment, data is recorded on acontactless IC on the data card. The card can then be returned to theflipper station 106. In one embodiment, the flipper station 106 rotatesand aligns the card in preparation for the printer module 110.

The printer module 110 can print graphics in either monochrome or colorvia a printer. In one embodiment, the printer uses a D2T2 thermalprocess to print on to the card. In other embodiments, other colorschemes and other thermal processes can be used. In several embodiments,the card is returned to the flipper station 106 and rotated again toallow the printer module 110 to print on both the top and bottom sidesof the card.

In one embodiment, the card is advanced from the printer module 110using a lateral card transport 112. The lateral card transport 112 canadvance the card to a card embosser 114. The card embosser 114 canemboss, indent, or print card personalization information as required oneither side of the card. The embosser can also emboss or print usingribbons. The card can be advanced from the embosser to the magneticfingerprint reference station 116. In many embodiments, the magneticfingerprint reference station 116 obtains information indicative of theunique characteristics of the magnetic field of the magnetic stripe. Inone embodiment, the information is obtained in accordance with themethods disclosed in U.S. Pat. No. 6,098,881 to Deland, Jr., et al. andU.S. patent application Ser. Nos. 11/014,930, 11/014,931 and 11/015,271which are hereby incorporated by reference in their entirety.

In several embodiments, the card is advanced to a foil tipping station118. The foil tipping station 118 can apply foil to certain embossedcharacters as called for by the card personalization information using ahot stamp process. The completed card can be advanced to a card exit andremoved by an operator of the card personalization system 100. Inanother embodiment, multiple cards are personalized in the system at thesame time. In yet another embodiment, the force applied by the foiltipper is varied using a controllable spring (not shown).

In several embodiments, appropriate preprinting of the card using theprinter module 110 and embossing of the card using the embosser 114replaces foil tipping operations. Using this method instead of foiltipping prevents the quick wear of foil tipped characters. Withtraditional foil tipping, the tipped metal can wear off in a rapidfashion. Using preprinting, an entire card surface can be painted ormetallized with the foil print prior to embossing. When the surface isembossed or indented, it is now stronger because the most elevatedportions of the characters have more than just foil tipping. The entirearea surrounding the elevated portions can be the same color and/ormaterial. In many embodiments, the print module prints using foilmaterials and/or inks of different colors. In many embodiments, the useof preprinting and embossing removes the need for the foil tippingstation 118.

Printer ribbons can be used by the printer module to personalize cardswith personalization information. A top view of a printer ribbon inaccordance with an embodiment of the invention is shown in FIG. 3 a. Theprinter ribbon 120 includes a black portion 122 and a metallic resinportion 124. In operation, the printer module 110 of FIG. 2 can use theblack portion 122 to provide background color, lettering, numbering,and/or other functions using the color black on the front and/or backsides of the card. Similarly, the printer module can use the metallicresin portion 124 to provide background color, lettering, numberingand/or other functions using metallic resin on the front and/or backsides of the card. In one embodiment, the printer ribbon 120 is used inindent and/or metallic printing by the printer module. The use of thedual portion printer ribbon having a metallic resin portion can avoidthe need for the foil tipping station 118.

In many embodiments, the dual portion printer ribbon of FIG. 3 a savesprinter ribbon material. Typically, the printer module uses an ordinaryblack printer ribbon of card width to print lettering on the back sideof a card and/or an ordinary metallized resin printer ribbon of cardwidth to metallize embossed letters on the front side of the card. Insuch case, only a portion of either ordinary printer ribbon is used. Inmany embodiments, the black and metallized resin portions are used onlyfor lettering confined to a region of the card. The unused portion ofeither ordinary printer ribbon is thus wasted material. The dual portionprinter ribbon can reduce the wasted material by at least half.

A top view of a printer ribbon in accordance with an embodiment of theinvention is shown in FIG. 3 b. The printer ribbon 130 includes a cyanportion 132, a magenta portion 134, a yellow portion 136, and a blackportion 138. In operation, printer module 110 of FIG. 2 can use the cyan132, magenta 134, yellow 136, and/or black 138 portions in any possiblecombination or individually to provide background color, lettering,numbering, and/or other appropriate functions. In one embodiment, theportions are mixed or combined to generate other colors in a processcalled dye sublimation. With this selection of colors, nearly all colorscan be produced by combination.

A top view of a printer ribbon in accordance with an embodiment of theinvention is shown in FIG. 3 c. The printer ribbon 140 includes a cyanportion 142, a magenta portion 144, a yellow portion 146, and a metallicresin portion 148. In operation, printer module 110 of FIG. 2 can usethe cyan 142, magenta 144, yellow 146, and/or metallic resin 148portions in any possible combination or individually to providebackground color, lettering, numbering, and/or other appropriatefunctions. In one embodiment, the portions are mixed or combined togenerate other colors using dye sublimation. With this selection ofcolors, a large variety of colors can be produced by combining colors.The use of a printer ribbon including a metallic resin portion can avoidthe need for the foil tipping station 118.

A top view of a printer ribbon in accordance with an embodiment of theinvention is shown in FIG. 3 d. The printer ribbon 150 includes a cyanportion 152, a magenta portion 154, a yellow portion 156, a metallicresin portion 158, and a black portion 160. In operation, the printermodule 110 of FIG. 2 can use the cyan 152, magenta 154, yellow 156,metallic resin 158 and/or black 160 portions in any possible combinationor individually to provide background color, lettering, numbering,and/or other appropriate functions. In one embodiment, the portions aremixed or combined to generate other colors using dye sublimation. Withthis selection of colors, a large variety of colors can be produced bycombining colors. The use of a printer ribbon including a metallic resinportion can avoid the need for the foil tipping station 118. As statedpreviously in the discussion of FIG. 3 a, a dual portion printer ribbon,including portions such as the metallic resin portion 158 and the blackportion 160, can reduce wasted printer ribbon material.

A perspective view of the card personalization system of FIG. 2 inaccordance with an embodiment of the invention is shown in FIG. 4. Themanual insertion slot 104 and retractable door for the dual card hopper102 can be seen from this view. A plastic or metallic case 101 canenclose the card personalization system. In many embodiments the case101 can be constructed from any variety of materials and is tamperresistant. In one embodiment, the case can be locked using a manual lockand/or software controlled locks. Furthermore, the case can includemounting holes to secure the card personalization system to a worksurface and sensors to detect attempts to tamper with the case.

A front view of the card personalization system of FIG. 4 is shown inFIG. 5. A card can be inserted into the manual insertion slot 104 toinitiate the personalization process within the card personalizationsystem. One or more cards may be placed within the machine by opening aretractable door to the dual card hopper 102 and placing the cardsinside the hopper. When a card has been completed it can exit themachine via the card exit 103. In alternative embodiments, other methodsof inserting a data card into the machine can be used.

A plan view of a card personalization system of FIG. 4 without the topis shown in FIG. 6. FIG. 6 illustrates the physical relationship of thecard hopper 102, encoder station 108, printer module 110, lateral cardsupport 112, card embosser 114, magnetic fingerprint reference station116, and foil tipping station 118. A card in the process of beingpersonalized essentially follows the card path 107 as it is guided alongthe path and advanced where necessary. For instance, the card can enterthe machine either through the manual insert slot 104 (shown in FIG. 4)or card hopper 102. The card can be advanced by motorized rollers in afirst direction to the flipper station 106 and to and from the encoderstation 108. The motorized rollers of the flipper station 106 (shown inFIG. 2) can advance the card to the printer module 110.

The motorized rollers of the lateral card transport 112 can advance thecard from the printer module to the card embosser 114 in a seconddirection. The second direction being perpendicular to the firstdirection. The lateral card transport can also align the card so as toachieve horizontal level and straight entry into the embosser 114. Anopto-sensor, not shown, can be used to align and confirm card edgeparallelism and overall straight transport of the card on the path. Themotorized rollers of the lateral card transport 112 can advance the cardin a third direction from the embosser to the magnetic fingerprintreference station 116. The third direction being parallel to the firstdirection. The motorized rollers can also advance the card to the foiltipping station 118 and eventually to a card exit.

A perspective view of a card embosser in accordance with an embodimentof the invention is shown in FIG. 7. The card embosser 300 includes twoembosser wheels 302, two hammer drive mechanisms and infill media 306.The embosser wheels 302 can include a number of font elements 308located at the ends of fingers 310 extending radially from a centralring 312. The hammer drive mechanisms can include motors 314, cams 316,pivot arms 318, rollers 320, and hammers 322.

In the illustrated embodiment, the mechanical force required to performembossing is provided by the pair of motors 314. In other embodiments, asingle motor can be used to drive both hammers. In the embodimentillustrated in FIG. 7, each hammer 322 is connected to a pivotallymounted pivot arm 318, which includes a roller 320 at the end of thepivot arm 318 opposite the hammer 322. The roller 320 rests on a cam 316that is connected to a motor 314. The motor 314 is capable of rotatingthe cam 316 and the rotation of the cam 316 by the motor 314 pivots thepivot arm 318 and drives the hammer 322 into a radially extended finger310. The ends of the fingers 310 each have a rectangular depression 309on the outer side of the end, where the outer side is the side furthestfrom the fingers of the other embosser wheel. The hammer 322 has amating rectangular protrusion 321 (see FIG. 8) configured to engage therectangular depression 309 for each finger 310. In other embodiments,the depressions and protrusions can take other geometric shapes orengage in other ways including the depression being located in thehammer and the protrusion located on the ends of the figures of theembosser wheel. The font elements 308 are positioned on the inner sideof the end of each finger, where the inner side is the side closest tothe fingers of the other embosser wheel. When both motors drive thehammers into opposing fingers of the embosser wheel 302, the two fingersare driven together, in a mating fashion, and emboss a character on thedata card. The font elements 308 at the end of each finger 310 eachspecify a different character to be embossed. The embosser wheels 302can be rotated to select the characters to be embossed.

The punch cycle of the driving hammer can be varied to generate maximumtorque at the end of the cycle. This can result in character bycharacter tuning of the embosser. In many embodiments, the arrangementof the opposing flexible fingers having depressions configured to engagethe hammer improves and/or ensures proper alignment of the hammer andfont elements during the embossing process. In one embodiment, anopto-sensor can be used to maintain alignment of the card within theembosser. This can enable self-calibration during the embossmentprocess. In one embodiment, the two motors can control the point ofcontact such that the point of contact is not at the midpoint or centerpoint between the hammers. This can help ensure uniformity in embossingdespite the variable quantity of force required to emboss a character.For example, an “8” typically requires more force to emboss or indentthan a “.”. In one embodiment, a force controller varies the force andpoint of contact of the hammers.

The fingers can be made of plastic, flexible metal or other suitablematerials. The hammers, rollers, pivot arms, cams and other embossercomponents can be made of metal or other suitably rigid materials.

A front view of a card embosser in accordance with an embodiment of theinvention is shown in FIG. 8. The card embosser 300 includes a pair ofretractable cartridges 306 holding spooled ribbons of infill media orprinter ribbons. Interposing a ribbon between font elements and the workpiece can result in the infill media being transferred to the work pieceduring the embossing of the work piece. In one embodiment, the infillmedia is a single color ink on a Mylar ribbon carrier. In otherembodiments, the infill media can be constructed with different coloredinks and/or coloring agents and using different materials.

The cartridges can both occupy what can be referred to as an infillposition. When a cartridge is in the infill position, then the ribbonwill be struck by a font element during embossing transferring infillmedia to the work piece. Motors 314 (shown in FIG. 7) can pivot theframes on which the cartridges are mounted, displacing the cartridges towhat can be referred to as a retracted position. In the retractedposition, the ribbon does not impede the path of the font element to thework piece. When both cartridges are in the retracted position, noinfill media will be transferred to the work piece during embossing.Movement of a cartridge from the infill position to the retractedposition involves rotating of the cartridge toward the interior of theembosser about a pivot point located at one end of the cartridge. In oneembodiment, the movement of the cartridge can be achieved using amotorized swing arm to pull the cartridge in a hinged line. In otherembodiments, other actuating mechanisms and hinging configurations canbe used. In many instances the actuating mechanism can be a solenoid.

In one embodiment, it is useful to vary the amount of force used topunch/emboss a character based on the style of character. For instance,punching a “.” will typically require less force than punching an “8”.In this way, only the required amount of force is used for eachparticular character. In addition, varying the point at which the fontelements meet can improve the consistency of character emboss height. Inone embodiment, the point at which the font elements meet is controlledby varying the timing of each of the motors 314 that drive the hammer322. In one embodiment, the card embosser 114 is designed such that itis easily removed and changed out with a new one.

A flowchart of a process for embossing a card in accordance with anembodiment of the invention is shown in FIG. 9. The embosser 300 canreceive a card 402. The embosser can then receive an associatedpersonalization string 404. The embosser can then analyze the firstcharacter of the string to be embossed 406. The embosser can then lookahead to the next character of the string to be embossed 408. Theembosser wheels can then be rotated for the character to be embossed410. The hammer drive mechanisms can be applied to emboss the currentcharacter 412. If the end of the string is reached (414), then theprocess is done 416. Otherwise, the embosser can look ahead to the nextcharacter to be embossed, 408, and repeat the process. In otherembodiments, other methods for embossing a string on a card can be used.Specifically, more efficient methods that take less time to complete theembossing process can be used. In one embodiment, the process can embosscharacters out of sequence to improve timing. In a number ofembodiments, the above processes are performed in different sequences.In several embodiments, a subset of the above processes are performedand/or additional processes are performed.

A block diagram of a memory system in accordance with an embodiment ofthe invention is shown in FIG. 10. Memory system 500 can be used by thecard personalization system 100 to store card personalizationinformation that can include credit card numbers, expiration dates, carduser's name, pictures, voice samples, fingerprints, personalphotographs, company logos, or any other personalization informationthat can be stored in a memory system. The card personalizationinformation can be stored sequentially in the memory or using linkedlists or other non-sequential data structures. The memory system 500 canalso be used by the card embosser to implement any methods of embossingrequiring memory. In one embodiment, the memory system 500 can take theform of a magnetic disk, magnetic tape, or digital memory. In anotherembodiment, the memory can store card personalization information, cardembosser configuration information, and the mechanical characteristicsof the system.

A block diagram of a card personalization system in accordance with anembodiment of the invention is shown in FIG. 11. The cardpersonalization system includes a dual card hopper 602, a manualinsertion slot 604, an encoder station 608, a printer module 610, alateral card transport 612, a card embosser/indent mechanism 614, atransfer module 616, a reject card hopper 618, a card exit transport620, an exit hopper 622 and card paths 607 and 609. The cardpersonalization system can personalize a variety of cards, blank orpre-initialized. The cards to be personalized can include a magstripecard, a smart card, a contactless card (i.e. RFID card), or othersuitable card. In operation, a card can follow the card path 607 when itis manually inserted into the manual insertion slot 604 or placed intothe dual card hopper 602. The card can then be forwarded to the encoderstation 608.

Once the card is encoded with some personalization information at theencoder station 608, the card can be forwarded to the printer module610. Once personalization information has been printed to the card atthe printer module, the card is forwarded to the lateral card transport612. The lateral card transport can forward the card to the cardembosser/indent mechanism 614. Once the card has been embossed and/orindented with personalization information, it can be forwarded to thetransfer module 616.

The transfer module 616 can be programmed with predetermined criteria asto the requirements for an acceptable card. The transfer module can beeither pre-programmed with acceptance criteria or it can receive theinstructions for acceptance criteria during operation. In the event thatthe card does not meet the acceptance criteria, it is forwarded to thereject card hopper 618 along the card path 609. In the event that thecard passes the acceptance criteria, the card is forwarded to the cardexit module 620 which transports the card to the exit hopper 622. Inmany embodiments, the components of the card personalization system aremodular and can be removed and/or additional components can be added. Inaddition, the order of the components may be rearranged.

In one embodiment, each hopper of the dual card hopper 602 can hold 50cards. In other embodiments, the hoppers can hold more than or less than50 cards.

The encoder station 608 can encode card personalization information on avariety of cards. The encoder station can encode personalizationinformation on a card having a magnetic stripe (magstripe card). In oneembodiment, the encoder station includes a magnetic fingerprint readercapable of capturing the magnetic fingerprint of the magstripe card inaccordance with methods describes in the afore-mentioned U.S. Pat. No.6,098,881. The encoder station is capable of communicating with otherdevices (i.e. server, central host) via a network or other means toacquire personalization information. The encoder can associate thepersonalization data of the intended card user with the card. Forexample, often personalization information for a credit card includesaccount number, expiration data, the name of the credit issuer, the typeof card, etcetera. In one embodiment, the encoder reads the uniquemagnetic fingerprint of a card and sends the magnetic fingerprintinformation to the central host to be associated with the card user'sfinancial or other identification related records. In such case, thesame card can be personalized with some of the card user'spersonalization information such as the financial or other relatedrecords.

In one embodiment, the encoder station encodes a smart card having anumber of electrical contacts on the card (i.e. IC card). The encoderstation can include a similar arrangement of electrical contactsconfigured to engage the electrical contacts of the smart card. Onceengaged, the encoder station can encode personalization information tothe smart card.

In one embodiment, the encoder station encodes a contactless card.Encoding of the contactless card can be achieved without contacting thecontactless card. In one embodiment, the encoder communicates with thecontactless card using radio frequency communications. In severalembodiments, the encoder uses the RFID method to communicate with acontactless card. In many embodiments, the encoder communicates with thecard using other known methods of wireless communication. In otherembodiments, the encoder station is capable of encoding any type of cardthat can be encoded with personalization information. Although in manyembodiments, the encoder station is streamlined to support a single typeof card.

Once the card has been through the encoding station, it enters theprinter module 610. The printer module 610 can print graphics in eithermonochrome or color via a printer. In one embodiment, the printer uses aD2T2 thermal process to print on to the card. In other embodiments,other color schemes and other thermal processes can be used. In severalembodiments, the card may be returned to a flipper station (not shown inFIG. 11) and rotated again to allow the printer module to print on boththe front and/or back sides of the card. The printer module can use anyof the printer ribbons depicted in FIGS. 3 a-3 d for printing cardpersonalization information onto the card.

Once the card has been through the printer module, it enters the lateralcard transport 612. The lateral card transport 612 can advance the cardfrom the print module towards the card embosser/indent mechanism 614. Inone embodiment, the lateral card transport holds and positions the cardwhile the embosser/indent mechanism operates on the card.

The card embosser/indent mechanism 614 can emboss, indent and/or printcard personalization information as required on either side of a card inaccordance with the description of FIG. 7.

Once the card has been through the card embosser/indent mechanism, itenters the transfer module 616. The transfer module 616 determineswhether the card meets predetermined acceptance criteria or queries adatabase to determine an acceptance criteria. If the transfer moduledetermines that the card meets predetermined acceptance criteria then itforwards the card to the card exit transport 620. The card exittransport 620 can transport the card to the exit hopper 622. If thetransfer module determines that the card does not meet the acceptancecriteria, then it forwards the card to the reject card hopper 618. Oncethe card is in the exit hopper or the reject card hopper, an operatorcan retrieve the card as necessary.

In one embodiment, the transfer module includes a foil tipping station.In the event that the card meets the acceptance criteria and requiresfoil tipping, the foil tipping station acts to apply foil to therequisite portion(s) of the card using a hot stamp process.

Each of the components of the card personalization system can be inphysical and/or electrical communication with a control system. FIG. 12shows a schematic block diagram of a card personalization systemincluding a control system in accordance with an embodiment of theinvention. The card personalization system includes a control system701, a dual card hopper 702, a manual insertion slot 704, an encoderstation 708, a printer module 710, a lateral card transport 712, aninput/output (I/O) module 713, a card embosser/indent mechanism 714, atransfer module 716, a touch screen 719, a card exit transport 720, anexit hopper 722, an access control unit 724, a reject card hopper 718,and an external device or network 715. The control system 701 isconnected to the dual card hopper 702, manual insertion slot 704,encoder station 708, printer module 710, lateral card transport 712,input/output (I/O) module 713, card embosser/indent mechanism 714,transfer module 716, touch screen 719, card exit transport 720, exithopper 722, access control unit 724, and reject card hopper 718. The I/Omodule 713 is connected to the external device or network 715. In oneembodiment, the I/O module 713 is wirelessly connected to the externaldevice or network 715.

The control system can be implemented using any combination ofmicroprocessors, memory, discrete logic components, data buses and/orother processing elements that share information. In one embodiment, thecontrol system includes devices capable of driving a number of steppermotors. In one embodiment, the control system controls the flow of powerto each of the components connected to it and can disable any of thosecomponents. In one embodiment, the control system communicatesinformation to each of the components connected to it.

In operation, the control system 701 communicates with the externaldevice or network 715 via the I/O module 713 to access or storeinformation related to card personalization. The external device ornetwork 715 can be a central host or server or other computing device.The method of communication can include Ethernet, fiber optic, wirelessor any other communication method known in the art for communicatingbetween two computing devices.

The access control unit 724 can include a magnetic fingerprint cardreader. The card personalization operator can swipe an authorizedmagstripe card to enable the operation of the card personalization unitand/or to gain access to the inside of the card personalization system.The control system 701 can disable all or some of the components that itcommunicates with until it has determined that the security informationfrom the swiped operator card matches information on a predeterminedauthorized operator list. To verify that an operator is authorized tooperate and/or to obtain access to the inside of the cardpersonalization unit, the control system 701 can query either a memorylocal to the card personalization device or control system or anexternal database available from the external database or network 715via the I/O module 713. In one embodiment, the control system verifiesthat the magnetic fingerprint of the swiped card is authorized.

In one embodiment, the operator uses the touch screen input device 719to enter access code information in addition to, or in place of, swipinga magstripe card. In this way, the control system determines whether ornot the machine operator is authorized to personalize a card.

The touch screen 719 can also be used to enter personalizationinformation such as the intended card holder's name or other identifyinginformation. The control system can use the identifying information toretrieve any or all of the intended card holder's records, if available,from the server or central host. In one embodiment, the operator canenter all the card personalization information necessary to personalizea card using the touch screen. In one embodiment, the card owner can usethe touch screen to personalize the card according to the owner'spersonal preferences. For example, the card user could select abackground, the card font, and/or pictures to be placed on the card. Inone embodiment, the touch screen is implemented using a liquid crystaldisplay or LCD. In other embodiments, other materials or componentssuitable to enabling touch screen input can be used.

The I/O module can be implemented using any combination ofmicroprocessors, memory, discrete logic components, data buses or otherprocessing elements that share information. The I/O module communicateswith the control system via any number of communication methods that caninclude buses, protocols, serial connections or any combination thereof.

A flowchart of a process for personalizing a data card in accordancewith an embodiment of the invention is shown in FIG. 13. The process 800starts when the card personalization system receives a data card 802.The system receives personalization information 804. The system encodesthe data card with at least some of the personalization information 806.The system reads the magnetic fingerprint of the data card 808. Thesystem stores the magnetic fingerprint of the data card 810. The systemprints at least some of the personalization information to the data card812. The system transports the data card from a first location to asecond location 814. The system embosses or indents the data card withat least some of personalization information 816. The system thendetermines whether the data card meets a predefined acceptance criteria820. In one embodiment, the system is programmed with the predeterminedacceptance criteria. In another embodiment, the system queries anexternal database to determine the predetermined acceptance criteria. Ifthe data card meets the acceptance criteria, then the system moves thedata card to an exit hopper 822. If the data card does not meet theacceptance criteria, then the system moves the data card to a rejectcard hopper 824. In many embodiments, the system processes any number ofdata cards. In many embodiments, the data card is transported from afirst location to a second location a number of times to enable varioussteps of the process 800.

A flowchart of a process for communicating with a card personalizationsystem in accordance with an embodiment of the invention is shown inFIG. 14. The process 850 begins when the server receives a request forpersonalization information including information identifying a carduser from a card personalization system 852. The server identifies arecord having personalization information based on the informationidentifying the card user 854. The server sends personalizationinformation to the card personalization system 856. The server receivesmagnetic fingerprint information for a data card associated with thecard user from the card personalization system 858. The server storesthe magnetic fingerprint information of the data card in conjunctionwith the record 860. In many embodiments, the server receives manyrequests and possibly simultaneously. In one embodiment, the serveridentifies a number of records based on the identification informationhaving personalization information. In many embodiments, the serverreceives requests from and sends personalization information to a cardpersonalization system acting as a client. In a number of embodiments,the above processes are performed in different sequences. In severalembodiments, a subset of the above processes are performed and/oradditional processes are performed.

Returning to the physical structure of a card personalization system, aperspective view of the card personalization system of FIG. 11 inaccordance with an embodiment of the invention is shown in FIG. 15. Inaddition to the components described previously, the cardpersonalization system includes a plastic or metallic case 900, asecurity door 902, and a key lock 904. The door and key lock providesecurity measures that ensure only authorized access to the internalcomponents of the system.

A plan view of the card personalization system of FIG. 15 without thetop in accordance with an embodiment of the invention is shown in FIG.16.

Variations, modifications, and other implementations of what isdescribed herein will occur to those of ordinary skill in the artwithout departing from the spirit and the scope of the invention asclaimed. Although the invention has been described with respect tocertain embodiments, it should be recognized that the invention includesthe claims and their equivalents supported by this disclosure.

1. A card personalization system comprising: a card receiver configuredto receive one or more data cards; a control system connected to thecard receiver, the control system configured to receive personalizationinformation; an encoder system connected to the control system, theencoder system configured to encode the one or more data cards with atleast some portion of the personalization information; a card readerconnected to the control system, the card reader configured to readmagnetic fingerprint information from the one or more data cards; andthe control system configured to store the magnetic fingerprintinformation.
 2. The card personalization system of claim 1, wherein thecontrol system is configured to communicate with a server.
 3. The cardpersonalization system of claim 2, wherein the control system isconfigured to receive personalization information from the server. 4.The card personalization system of claim 2, wherein the control systemis configured to send the magnetic fingerprint to the server.
 5. Thecard personalization system of claim 1, further comprising a cameraconnected to the control system, the camera configured to acquirepersonalization information or to identify an authorized user of thecard personalization system.
 6. The card personalization system of claim1, further comprising a fingerprint scanner connected to the controlsystem, the fingerprint scanner configured to acquire personalizationinformation or to identify an authorized user of the cardpersonalization system.
 7. The card personalization system of claim 1,further comprising a microphone connected to the control system, themicrophone configured to acquire personalization information or toidentify an authorized user of the card personalization system.
 8. Thecard personalization system of claim 1, further comprising a retinascanner connected to the control system, the retina scanner configuredto acquire personalization information or to identify an authorized userof the card personalization system.
 9. The card personalization systemof claim 1, further comprising an input device connected to the controlsystem, the input device configured to enable a card user to customizeone of the one or more data cards or to identify an authorized user ofthe card personalization system.
 10. The card personalization system ofclaim 9, wherein the input device comprises a touch screen.
 11. The cardpersonalization system of claim 1, wherein the control system isconfigured to determine whether any one of the one or more data cardmeets a predetermined acceptance criteria.
 12. The card personalizationsystem of claim 1, wherein each of the one or more data cards comprisesa magnetic stripe, and wherein the magnetic fingerprint information of aparticular one of the one or more data cards comprises a remanent noisecharacteristic of the magnetic stripe of the particular data card.
 13. Acard personalization system comprising: a card receiver configured toreceive one or more data cards; a control system connected to the cardreceiver, the control system configured to receive personalizationinformation; an encoder system connected to the control system, theencoder system configured to encode the one or more data cards with atleast some portion of the personalization information; a printerconnected to the control system, the printer configured to print atleast some portion of the personalization information to the one or moredata cards; and the printer configured to print using a printer ribboncomprising one or more portions, where at least one portion include ametallized resin portion
 14. The card personalization system of claim13, wherein the one or more portions comprise a black portion and ametallized resin portion.
 15. The card personalization system of claim14, wherein the printer ribbon has a rectangular shape having two shortsides and two long sides, the two short sides comprising a beginning andan end, and wherein the black portion and the metallized resin portionare rectangular and extend from the beginning to the end of the printerribbon.
 16. The card personalization system of claim 13, wherein the oneor more portions comprise a cyan portion, a magenta portion and a yellowportion.
 17. The card personalization system of claim 16, wherein theone or more portions further comprise a black portion.
 18. The cardpersonalization system of claim 16, wherein the one or more portionsfurther comprise a portion divided into a half black portion and a halfmetallized resin portion.
 19. The card personalization system of claim13, wherein the one or more portions further comprise a portion dividedinto a half black portion and a half metallized portion.
 20. A systemfor embossing a data card comprising: a first embosser wheel having aplurality of radially extending fingers, each of the fingers configuredto receive a first hammer mechanism and to impart a character to thedata card; a second embosser wheel having a plurality of radiallyextending fingers, the fingers configured to receive a second hammermechanism and to impart a character to the data card; a first motorconfigured to drive the first hammer mechanism; and a second motorconfigured to drive the second hammer mechanism.
 21. The system of claim20, wherein the fingers are made of a flexible material.
 22. The systemof claim 21, wherein the fingers are made of plastic.
 23. The system ofclaim 20, wherein the first hammer mechanism comprises a linkageconnected to a first driving hammer, and wherein the second hammermechanism comprises a linkage connected to a second driving hammer. 24.The system of claim 23, further comprising a controller configured tocontrol a point of contact between the first driving hammer and thesecond driving hammer.
 25. The system of claim 20, further comprising acontroller configured to control the movement of the first hammermechanism and the second hammer mechanism in a punch cycle, and whereinthe controller is configured to vary the punch cycle to generate maximumtorque at the end of the cycle.
 26. The system of claim 20, furthercomprising a controller configured to control the movement of the firsthammer mechanism and the second hammer mechanism in a punch cycle, andwherein the controller is configured to vary the punch cycle accordingto the type of character to be embossed.
 27. The system of claim 20,wherein each of the fingers of the first embosser wheel comprises afirst font element, and wherein each of the fingers of the secondembosser wheel comprises a second font element, and wherein the firstfont elements are configured to mate with the second font elements. 28.A method of personalizing a data card, comprising: receiving a datacard; receiving personalization information; encoding the data card withat least some portion of the personalization information; reading amagnetic fingerprint of the data card; and storing the magneticfingerprint.
 29. The method of claim 28, further comprisingcommunicating with a server.
 30. The method of claim 29, whereinreceiving personalization information comprises receivingpersonalization information from the server.
 31. The method of claim 29,further comprising sending the magnetic fingerprint to the server. 32.The method of claim 28, further comprising identifying an operatorauthorized to personalize the data card.
 33. The method of claim 28,wherein receiving personalization information comprises receivingpersonalization information from a device configured to accept inputfrom a user.
 34. The method of claim 28, further comprising printing atleast some portion of the personalization information to the data card.35. The method of claim 34, further wherein printing at least someportion of the personalization information to the data card comprisesusing a printer ribbon comprising a black portion and a metallized resinportion.
 36. The method of claim 28, further comprising embossing thedata card with at least some portion of the personalization information.37. The method of claim 36, wherein embossing the data card comprisesembossing the data card with at least some portion of thepersonalization information using two driving hammers, the methodfurther comprising controlling the point of contact between the twodriving hammers such that the point of contact is not at the midpoint.38. The method of claim 36 wherein embossing the data card with at leastsome portion of the personalization information comprises using a punchcycle, the method further comprising varying the punch cycle to generatemaximum torque at the end of the cycle.
 39. The method of claim 36,wherein embossing the data card with at least some portion of thepersonalization information comprises: receiving a personalizationstring of one or more characters; analyzing a first character of thestring to be embossed; looking ahead to the next character in the stringto be embossed; rotating one or more embosser wheels; and applying oneor more drive hammers.
 40. The method of claim 28, further comprisingdetermining whether the data card meets a predetermined acceptancecriteria.
 41. A method of personalizing a data card comprising:receiving a data card; receiving personalization information; encodingthe data card with at least some portion of the personalizationinformation; reading a magnetic fingerprint of the data card; storingthe magnetic fingerprint; printing at least some portion of thepersonalization information to the data card; transporting the data cardfrom a first location to a second location; embossing or indenting thedata card with at least some portion of the personalization information;and determining whether the data card meets a predetermined criteriaand, if not, rejecting the card.
 42. A method of communicating with acard personalization system comprising: receiving a request forpersonalization information, the request comprising informationidentifying a card user; identifying a record based on the informationidentifying the card user, the record comprising personalizationinformation; sending the personalization information; receiving magneticfingerprint information for a data card associated with the card user;and storing the magnetic fingerprint information in conjunction with therecord.
 43. The method of claim 42, wherein receiving a request forpersonalization information comprises receiving a request forpersonalization information from the card personalization system, andwherein sending the personalization information comprises sending thepersonalization information to the card personalization system.